High tensile grid module for use in concrete construction and method of use

ABSTRACT

A plurality of concrete reinforcing grid modules each comprising a plurality of spaced longitudinal wires and a plurality of spaced transverse wires may be nestably stacked together and sold as a package. The transverse wires are secured to the longitudinal wires at intersections. Each grid module may be secured to other like grid modules without the use of tools or additional material because least some of the grid module wires have tail portions at the ends thereof which interlock with the wires of other grid modules.

FIELD OF THE INVENTION

This invention relates generally to a method and apparatus for use insteel reinforced concrete construction and, more particularly, to apre-assembled stackable grid module and associated method of use.

BACKGROUND OF THE INVENTION

One of the most prevalent articles used to reinforce concrete structuresis a steel reinforcing bar, commonly abbreviated and referred to as“rebar.” Rebar is useful in constructing a variety of residential andcommercial structures including building foundations, dams, parkinggarages, retaining walls, bridges, garages and sidewalks. Specifically,rebar is used to reinforce concrete structures exposed to heavy tensile,compressive and shear stresses. Conventional rebar is milled intocylindrical rods of substantial length which may include ribs.

Such long reinforcing bars are difficult to load and transport.

The rods must be cut to the appropriate size and individually placed inposition in a reinforcing mesh and the intersections individually tiedor otherwise affixed together as shown in U.S. Pat. Nos. 5,881,460 and6,128,882 for example. Constructing reinforcing meshes for irregularlyshaped areas is often difficult, requiring the cutting, bending andfitting of the bars or rods to adapt to the irregular dimensions andcontours of the areas.

Another known product for concrete reinforcement is rolled wire mesh.Such rolls are difficult to flatten and wants to return to its rolled,curved condition. Such wire mesh must be cut to its desired size andappropriately positioned prior to the pouring of the concrete, a laborintensive task.

For constructing walk ways and patio floors, concrete is typicallypoured in 3.5 to 4.5 inch thick forms having wire products or rebarcentered in the concrete pad to improve the strength of the concrete. Ifthe strengthening member is a wire mesh, it must be positioned in theright position relative to the ground or substrate. Consequently, thewires of the mesh are inserted and held in receptacles in what are knownin the industry as chairs or risers. During the pouring of the wetconcrete these chairs or risers often are knocked over or moved by theweight of the wet concrete, thereby moving the wire strengtheningmembers to undesirable locations. This may lead to weak spots in theconcrete once it hardens which are susceptible to cracks subsequently.

U.S. Pat. No. 3,950,911 discloses modular units or grids of reinforcingmesh which are small enough to be carried by an individual and may beconnected to reinforce concrete. However, such modular grids, like otherpieces of rebar, are made of conventional wire having a tensile strengthof between 65,000 and 75,000 pounds per square inch (“psi”) which is theASTM standard. When a concrete worker walks on such wire grids duringthe pouring and layout process, the wire grid will deform in anundesirable manner.

In order to eliminate such deformation of a concrete reinforcing gridmodule which may easily connected to similar grid modules is neededwhich will bounce back or return to its original position after the loadplaced therein is removed. Therefore, there is a need for a concretereinforcement product which will not deform when loaded with a person'sweight, which is small enough to be carried by an individual and may benestably stacked for storage purposes.

SUMMARY OF THE INVENTION

This invention comprises a nestably stackable concrete reinforcementgrid module which is made of high tensile strength steel and may quicklyand easily be connected to similar like grid modules.

The nestably stackable concrete reinforcement grid module comprises aplurality of spaced longitudinal wires extending longitudinally alongthe length of the concrete reinforcement grid module and a plurality ofspaced transverse wires extending transversely along the width of theconcrete reinforcement grid module, each transverse wire intersectingeach of the spaced longitudinal wires of the grid module. The wires arepreferably welded together at their intersections, but may be securedtogether is any desired manner.

In one embodiment, each of the transverse wires has a linear middleportion and tail portions at the ends of thereof for locking or securingtogether multiple grid modules. However, the transverse wires may assumeother shapes or configurations. Similarly, some of the longitudinalwires have a linear middle portion and tail portions at the ends ofthereof for locking together multiple grid modules while otherlongitudinal wires are generally corrugated along their lengths, havingflattened peaks and flattened valleys joined by connectors. Theflattened valleys of the longitudinal wires of the grid module rest onthe ground or substrate for purposes of stabilizing the grid module,thereby eliminating any need for chairs or supports prior to pouring theconcrete.

In at least some of the wires, tail or end portions extend downwardlyfrom adjacent portions of the wire at an angle of 30-45 degrees relativeto the adjacent portion of wire. The tail portions are used tointerconnect or interlock multiple like grid modules together withoutthe use of fasteners or tools of any sort.

In one embodiment, each of the wires is made of ten gauge high tensilestrength wire which provides for additional pull strength preventingsections of the concrete from separating if cracked. Other gauge ordiameter wires may be used if desired. The tensile strength of the wiresis greater than 75,000 psi and preferably approximately 100,000 psi.Such high tensile wires allow the grid module to spring back or returnto its original position if stepped on during the concrete formingprocess.

Any number of pre-welded grid modules of the present invention may benestably stacked together into a stack and placed inside a cardboardcollar. The collar may have assembly instructions or other indiciaprinted on the outside surface thereof for marketing purposes.Alternatively, any number of pre-welded grid modules of the presentinvention may be combined into a stack and the stack surrounded with acardboard collar.

Plastic or metal collars may be then wrapped around the cardboard collarand stack of grid modules to create an attractive package for sale to acustomer.

In operation, a person may open the package by cutting the collars andthen removing one or more grid modules from the stack of grid modules.Multiple grid modules may be interlocked together inside a concrete formusing the edge lock feature of the grid modules of the present inventionbefore the concrete is poured.

The configuration of the pre-welded grid module of the present inventionallows a user to easily and quickly assembly a concrete reinforcementgrid of a desired size prior to pouring concrete in a pre-assembledform, as is known in the art.

These and other objects and advantages of the present invention will bemore readily apparent from the following description of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a package of nestably stacked concretereinforcing grid modules constructed in accordance with the presentinvention;

FIG. 2 is a perspective view of a stack of packages like the packageshown in FIG. 1;

FIG. 3A is a perspective view of a first concrete reinforcing gridmodule constructed in accordance with the present invention resting in aform and a second concrete reinforcing grid module being secured to thefirst concrete reinforcing grid module in the form;

FIG. 3B is a perspective view of the first and second concretereinforcing grid modules of FIG. 3A secured together inside the form;

FIG. 4A is a view taken along the line 4A-4A of FIG. 3B;

FIG. 4B is an enlarged view of a portion of FIG. 4A;

FIG. 5A is a side elevational view partially in cross-section of amethod of creating a stack of concrete reinforcing grid modules inside acollar; and

FIG. 5B is a side elevational view partially in cross-section of apackage of concrete reinforcing grid modules constructed as shown inFIG. 5A.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to the drawings, and particularly to FIG. 1, there isillustrated a package 10 including a stack 12 of identical concretereinforcing grid modules 14 inside a generally rectangular cardboardcollar 16 and two bands 18 surrounding the stack 12 of concretereinforcing grid modules 14 and cardboard collar 16. Although two bands18 are shown surrounding the stack 12 of concrete reinforcing gridmodules 14 and collar 16, any number of bands may be used in any desiredorientation or manner. The outside surface 19 of the cardboard collar 16preferably has indicia 20 such as instructions and trademark materialprinted thereon. The present invention may be packaged in another mannerusing other materials if desired.

FIG. 2 illustrates a plurality of packages 10 as shown in FIG. 1 stackedon top of each other to create a bundle 22 of packages 10.

Referring to FIG. 3A, one embodiment of nestably stackable concretereinforcing grid module 14 has a transverse dimension or width W, alongitudinal dimension or length L and a height H. See FIG. 4B. In oneembodiment, the grid module is 34 inches wide, 46 inches long and twoinches tall. These dimensions are preferable for using the grid modulesin walk ways or patio floors which are either three or four feet widebecause no cutting is necessary. However, any other size concretereinforcement grid module made in accordance with the present inventionmay be used to make a grid for reinforcing concrete.

The nestably stackable concrete reinforcing grid module 14 comprises aplurality of transverse wires 24 extending in a transverse direction(from side-to-side), each having a straight or linear middle portion 26and a pair of end or tail portions 28 at opposed ends of the transversewire 24. Each tail portion 28 extends outwardly and downwardly at anangle of 30-45 degrees from the straight middle portion 26 of thetransverse wire 24. However, other angles may be used if desired.

The nestably stackable concrete reinforcing grid module 14 furthercomprises a plurality of longitudinal wires 30 extending in alongitudinal direction or from end-to-end of the module 14. Theoutermost longitudinal wires 31 each have a straight or linear middleportion 32 and a pair of tail or end portions 34 at opposed ends of thelongitudinal wire 31, like each of the transverse wires 24. Each tailportion 34 extends outwardly and downwardly at an angle of 30-45 degreesfrom the straight middle portion 32 of the outermost longitudinal wire31. However, the tail portion 34 may extend downwardly from the middleportion 32 at any desired angle. Similarly, nestably stackable concretereinforcing grid module 14 further comprises two internal longitudinalwires 36, each having a straight or linear middle portion 38 and a pairof tail or end portions 40 at opposed ends of the internal longitudinalwire 36. Each tail portion 40 extends outwardly and downwardly at anangle of 30-45 degrees from the straight middle portion 38 of theinternal longitudinal wire 36. However, the tail portion 40 may extenddownwardly from the middle portion 38 at any desired angle.

The nestably stackable concrete reinforcing grid module 14 furthercomprises a pair of longitudinal wires 42 extending in a longitudinaldirection, each longitudinal wire 42 being located between one of theoutermost longitudinal wires 31 and the internal longitudinal wires 36and secured to each of the transverse wires 24. The longitudinal wires42 each are generally corrugated along their length and have generallyco-planar flattened peaks 44 and generally co-planar flattened valleys46 joined together with connectors 48. Each longitudinal wire 42 has apair of tail or end portions 50 at opposed ends of the generallycorrugated longitudinal wire 42 adjacent and extending outwardly anddownwardly at an angle of 30-45 degrees from one of the peaks 44 of thelongitudinal wire 42. However, the tail portion 50 may extend downwardlyfrom the one of the peaks 44 at any desired angle.

Although the figures show five transverse wires 24 and five longitudinalwires 30 including two generally corrugated longitudinal wires 42 in thenestably stackable concrete reinforcing grid module 14, any number oftransverse or longitudinal wires may be incorporated into a nestablystackable concrete reinforcing grid module in accordance with thepresent invention. Similarly, although the figures show each wire havingtail portions at each end thereof, tail portions may be omitted from oneor more ends of one or more wires if desired.

As illustrated in FIGS. 3A and 3B, a first nestably stackable concretereinforcing grid module 14 a is placed on the ground or substrate 52inside a wooden form 54. A second nestably stackable concretereinforcing grid module 14 b is placed on the ground or substrate 52inside the wooden form 54 so that the tail portions of the longitudinalwires 30 of the second nestably stackable concrete reinforcing gridmodule 14 b interlock with an outermost transverse wire 24 a of thefirst nestably stackable concrete reinforcing grid module 14 a, therebyconnecting the first and second nestably stackable concrete reinforcinggrid modules 14 a, 14 b inside the form 54. See FIG. 3B. As shown inFIG. 4B, the tail portions of the longitudinal wires 30 of the secondnestably stackable concrete reinforcing grid module 14 b lay over anoutermost transverse wire 25 of the first nestably stackable concretereinforcing grid module 14 a, thereby joining the first and secondnestably stackable concrete reinforcing grid modules 14 a, 14 b insidethe form 54.

Although not shown, the tail portions 28 of the transverse wires 24 ofany of the nestably stackable concrete reinforcing grid modules mayinterlock with an outermost longitudinal wire of an adjacent nestablystackable concrete reinforcing grid module, thereby connecting theadjacent nestably stackable concrete reinforcing grid modules in aside-by-side manner inside a form before the concrete is poured.

As shown in FIGS. 4A and 4B, at least a portion of the flattened valleys46 of the generally corrugated longitudinal wires 42 of each grid module14 a, 14 b rest on or are supported by the ground or substrate 52.

FIGS. 5A and 5B illustrate another method of making a package ofconcrete reinforcing grids in accordance with the present invention.Referring to FIG. 5A, a plurality of grid modules 14 c are similarlyaligned with the flattened valleys 46 c of the grid modules 14 c locatedabove the flattened peaks (hidden in FIGS. 5A and 5B) and outermostlongitudinal wires 31 c of each of the grid modules 14 c. Similarly, aplurality of grid modules 14 d are similarly aligned with the flattenedvalleys 46 d of the grid modules 14 d located below the flattened peaks(hidden in FIGS. 5A and 5B) and outermost longitudinal wires 31 d ofeach of the grid modules 14 d. As depicted by arrows 56, the gridmodules 14 c are lowered and intermesh with the spaced grid modules 14 dto form a stack 58. In the stack 58, every other grid module 14 c isturned upside relative to those grid modules 14 d adjacent to it. SeeFIG. 5B. This type of stacking arrangement creates a stack 58 havingflattened surfaces which may be surrounded with a collar 16 and easilybanded in a tight, efficient manner. See FIG. 1.

Although I have described one preferred embodiment of the invention, Ido not intend to be limited except by the scope of the following claims.

1. A nestably stackable concrete reinforcing grid module comprising: aplurality of spaced longitudinal wires, some of said longitudinal wiresbeing generally corrugated along their lengths including flattened peaksand valleys; a plurality of spaced transverse wires secured to saidlongitudinal wires at intersections; wherein at least some of said wireshave tail portions at the ends thereof for locking together multiplegrid modules.
 2. The concrete reinforcing grid module of claim 1,wherein said wires are made of high tensile strength steel.
 3. Theconcrete reinforcing grid module of claim 1 wherein said tail portionsare bent down relative to adjacent portions of each of said wires. 4.The concrete reinforcing grid module of claim 3 wherein said endportions are bent down 30-45 degrees relative to said adjacent portionsof said wires.
 5. The concrete reinforcing grid module of claim 1wherein each of said transverse wires has a linear middle portionbetween the tail portions.
 6. The concrete reinforcing grid module ofclaim 1 wherein said transverse wires are secured to said flattenedpeaks of said longitudinal wires.
 7. The concrete reinforcing gridmodule of claim 1 wherein wires of said grid module have a tensilestrength greater than 75,000 psi.
 8. The concrete reinforcing gridmodule of claim 1 wherein each of said wires of said grid module have atensile strength of approximately 100,000 psi.
 9. The concretereinforcing grid module of claim 1 wherein each of said wires of saidgrid module are welded together.
 10. A nestably stackable concretereinforcing grid module comprising: a plurality of spaced longitudinalwires; a plurality of spaced transverse wires welded to saidlongitudinal wires at intersections; wherein at least some of said wiresare made of high tensile strength wire having a tensile strength ofgreater than 75,000 psi.
 11. The concrete reinforcing grid module ofclaim 10 wherein at least some of said wires have tail portions at theends thereof for locking together multiple grid modules.
 12. Theconcrete reinforcing grid module of claim 10 wherein at least some ofsaid longitudinal wires are generally corrugated along their lengths andhave flattened peaks and valleys.
 13. The concrete reinforcing gridmodule of claim 12 wherein said transverse wires are welded to saidflattened peaks of said longitudinal wires.
 14. The concrete reinforcinggrid module of claim 10 wherein all of said wires have a tensilestrength of greater than 75,000 psi.
 15. The concrete reinforcing gridmodule of claim 10 wherein all of said wires have tail portions at theends thereof for locking together multiple grid modules.
 16. A packageof nestably stacked concrete reinforcing grid modules, said packagecomprising: a stack of welded concrete reinforcing grid modules, each ofsaid concrete reinforcing grid modules comprising: spaced longitudinalwires; a plurality of spaced transverse wires welded to saidlongitudinal wires at intersections; wherein at least some of said wireshave tail portions at the ends thereof for locking together multiplegrid modules; and a collar surrounding said stack of welded concretereinforcing grid modules.
 17. The package of claim 16 further comprisingcollars surrounding said stack of welded concrete reinforcing gridmodules and said collar.
 18. The package of claim 16 wherein said collaris made of cardboard and has information printed thereon.
 19. Thepackage of claim 16 wherein each of said concrete reinforcing gridmodules is made of wire having a tensile strength greater than 75,000psi.
 20. The package of claim 16 wherein each of said concretereinforcing grid modules is made of wire having a tensile strength ofapproximately 100,000 psi.
 21. A method of making a concrete reinforcinggrid comprising: providing first and second nestably stackable concretereinforcing grid modules, each of said modules comprising: a pluralityof spaced longitudinal wires, some of said longitudinal wires beinggenerally corrugated along their lengths including flattened peaks andvalleys; a plurality of spaced transverse wires secured to saidlongitudinal wires at intersections; wherein at least some of said wireshave tail portions at the ends thereof for locking together multiplegrid modules; placing said first grid module on a substrate such thatsaid flattened valleys of said first grid module contact the substrate;placing said second grid module on the substrate such that saidflattened valleys of said second grid module contact the substrate andsaid tail portions of said second grid module overlie an outermost wireof said first grid module.